EP4465432A2 - Encapsulation d'élément de batterie permettant la détection précoce d'emballement thermique de batterie - Google Patents

Encapsulation d'élément de batterie permettant la détection précoce d'emballement thermique de batterie Download PDF

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Publication number
EP4465432A2
EP4465432A2 EP24151564.2A EP24151564A EP4465432A2 EP 4465432 A2 EP4465432 A2 EP 4465432A2 EP 24151564 A EP24151564 A EP 24151564A EP 4465432 A2 EP4465432 A2 EP 4465432A2
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EP
European Patent Office
Prior art keywords
battery
gas
range
battery cell
outgassing material
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
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EP24151564.2A
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German (de)
English (en)
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EP4465432A3 (fr
Inventor
Phllip C. FOSTER
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Honeywell International Inc
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Honeywell International Inc
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Publication of EP4465432A2 publication Critical patent/EP4465432A2/fr
Publication of EP4465432A3 publication Critical patent/EP4465432A3/fr
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/30—Arrangements for facilitating escape of gases
    • H01M50/375—Vent means sensitive to or responsive to temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/4207—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/488—Cells or batteries combined with indicating means for external visualization of the condition, e.g. by change of colour or of light density
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/52—Removing gases inside the secondary cell, e.g. by absorption
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/124—Primary casings; Jackets or wrappings characterised by the material having a layered structure
    • H01M50/1245—Primary casings; Jackets or wrappings characterised by the material having a layered structure characterised by the external coating on the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/131—Primary casings; Jackets or wrappings characterised by physical properties, e.g. gas permeability, size or heat resistance
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/14—Primary casings; Jackets or wrappings for protecting against damage caused by external factors
    • H01M50/143—Fireproof; Explosion-proof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/471—Spacing elements inside cells other than separators, membranes or diaphragms; Manufacturing processes thereof
    • H01M50/48—Spacing elements inside cells other than separators, membranes or diaphragms; Manufacturing processes thereof characterised by the material
    • H01M50/486—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4271—Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4278—Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2200/00—Safety devices for primary or secondary batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • Various embodiments of the present disclosure relate battery cell encapsulation, and more particularly to treatment of polymer films that allow for early indication of thermal runaway.
  • Thermal runaway of batteries such as lithium ion batteries
  • batteries When a battery is subjected to conditions that can cause an irreversible exothermic chain reaction within the battery, fires or violent explosions can result from thermal runaway.
  • Electric vehicle manufacturers utilize battery management systems to monitor electrical conditions in battery banks, but in many cases the monitoring does not provide sufficient notice prior to thermal runaway to give occupants sufficient time to react to the situation safely and appropriately. There is a need for a means to predict a thermal runaway event with as much predictive time as possible.
  • a battery cell unit comprises a battery cell body, and outgassing material encapsulating the battery cell body, wherein (i) the outgassing material comprises a compound that emits one or more off-gasses at a range of off-gas temperatures, (ii) the range of off-gas temperatures is associated with a thermal runaway pending event, and (iii) the one or more off-gasses are detectable by a gas sensor.
  • the gas sensor comprises at least one of: a metal oxide sensor, an electrochemical sensor, a total volatile organic compound sensor, or an aerosol sensor.
  • the outgassing material comprises a polymer film incorporated with one or more chemical components including a specific vapor pressure associated with the range of off-gas temperatures.
  • the outgassing material comprises a thermochromic additive.
  • the outgassing material comprises one or more polymers.
  • the outgassing material comprises one or more polyolefins including at least one of: polyethylene, polyvinyl chloride, polypropylene, ethylene-vinyl acetate, or polychlorotrifluoroethylene (PCTFE).
  • the range of off-gas temperatures is below a temperature associated with the thermal runaway event. In some embodiments, the range of off-gas temperatures is below a temperature associated with cell venting. In some embodiments, the range of off-gas temperatures comprises a range of 120°C-140°C (248°F - 284°F). In some embodiments, a chemical component is incorporated separately into the outgassing material modifying its outgassing properties comprising the range of off-gas temperatures.
  • a battery system comprises a battery pack comprising one or more battery cells, the one or more battery cells comprising a battery cell body and outgassing material encapsulating the battery cell body, wherein (i) the outgassing material comprises a compound that emits one or more off-gasses at a range of off-gas temperatures, (ii) the range of off-gas temperatures is associated with a thermal runaway pending event, and (iii) the one or more off-gasses are detectable by a gas sensor, the gas sensor configured to detect the off-gas, and a battery management system coupled to the gas sensor, the battery management system configured to perform one or more actions based on a detection of the off-gas.
  • the gas sensor is further configured to transmit a signal to the battery management system, the signal comprising an indication that at least one of the one or more battery cells has reached the range of off-gas temperatures based on the detection of the off-gas.
  • the one or more actions comprise disabling utilization of the battery pack.
  • the one or more actions comprise generating a warning signal.
  • the gas sensor comprises at least one of: a metal oxide sensor, an electrochemical sensor, a total volatile organic compound sensor, or an aerosol sensor.
  • the outgassing material comprises a polymer film incorporated with one or more chemical components including a specific vapor pressure associated with the range of off-gas temperatures.
  • the outgassing material comprises one or more polymers. In some embodiments, the outgassing material comprises one or more polymers. In some embodiments, the range of off-gas temperatures is below a temperature associated with the thermal runaway event. In some embodiments, the range of off-gas temperatures is below a temperature associated with cell venting. In some embodiments, the range of off-gas temperatures comprises a range of 248°F - 266°F.
  • a method comprises sampling, by a computing device, off-gas measurement data from a gas sensor, the off-gas measurement data associated with a battery package comprising one or more battery cells and outgassing material encapsulating the battery cell body, wherein (i) the outgassing material comprises a compound that emits one or more off-gasses at a range of off-gas temperatures, (ii) the range of off-gas temperatures is associated with a thermal runaway pending event, and (iii) the one or more off-gasses are detectable by the gas sensor.
  • the method further comprises determining, by the computing device, a temperature or a rate of temperature change of the one or more battery cells based on the off-gas measurement data, determining, by the computing device, a thermal runaway pending event based on the temperature or the rate of temperature change of the one or more battery cells, and performing, by the computing device, one or more actions based on the thermal runaway pending event.
  • the term "comprising” means including but not limited to and should be interpreted in the manner it is typically used in the patent context. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of.
  • ком ⁇ онент or feature may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that a specific component or feature is not required to be included or to have the characteristic. Such a component or feature may be optionally included in some embodiments, or it may be excluded.
  • thermal runaway detection for batteries.
  • conventional methods for detecting thermal runaway such as the use of temperature sensors to detect temperature changes from batteries resulting from a lead up to a thermal runaway event, are not designed to detect early stages of thermal runaway.
  • the amount of time for which a gas sensor can predict thermal runaway events depends on a host of factors including specific abuse conditions (puncture vs. overcharge vs. overheating, for example), battery composition type, battery electrolyte system used, state of charge of the battery, location of the sensor relative to the defective battery, and response time of the sensor.
  • Lithium ion battery thermal runaway typically starts to occur at approximately 150°C (302°F), and cell venting typically starts to occur at approximately 134°C (272°F), as depicted in FIG. 1 .
  • Cell venting may refer to an emission of gasses from a battery cell resulting from a rupturing of the battery cell which may be caused by excessive pressure accumulated within the battery cell due to excessive operating temperature.
  • a thermal runaway may refer to an uncontrolled exothermic chemical reaction which is manifested by a rapid rise in local temperature of a battery cell. Once thermal runaway occurs, a battery cell may self-destruct and establish the conditions for a vehicle fire.
  • Cell venting may occur as a result of a rise in gas pressure in a battery cell.
  • the rise in gas pressure may be a function of temperature such that cell venting detection can be considered a surrogate temperature indicator.
  • detecting cell venting e.g., gas detection or aerosol detection
  • the detection of cell venting may provide monitoring of both temperature as well as gas emission from battery cells.
  • a disadvantage of detecting cell venting is that the chemical makeup of gasses vented from a cell may be dependent primarily on the electrolyte system used in the battery, and as such, the detection of cell venting via a gas sensor may be dependent upon the sensor technology and its sensitivity to specific gasses, as well as its cross-sensitivity to other gasses present in the ambient environment such as exhaust vapors or smog which can contain ozone, nitrogen oxides, carbon dioxide, carbon monoxide, and volatile organic compounds (VOC).
  • VOC volatile organic compounds
  • a system may be configured to detect off-gassing of a selected outgassing material, such as a polymer film used to encapsulate battery cells of a battery pack.
  • a selected outgassing material such as a polymer film used to encapsulate battery cells of a battery pack.
  • polymer film usable to encapsulate battery cells include, but are not limited to, polymers including polyolefins, such as polyethylene, polyvinyl chloride, polypropylene, ethylene-vinyl acetate, PCTFE, and other types of polymers known to one of ordinary skill in the art.
  • the selected outgassing material may comprise one or more synthetic fabrics or elastomers.
  • a battery may refer to a battery pack comprising one or more battery cells of any type.
  • Example battery cell types include, but are not limited to, lithium ion (e.g., lithium iron phosphate vs. lithium nickel cobalt aluminum oxide vs. lithium manganese oxide vs. lithium cobalt oxide), lead-acid, nickel-cadmium, nickel-metal hydride, to name a few.
  • the outgassing material may comprise a range of off-gas temperatures that is associated with a thermal runaway pending event, and a known specific material or compound capable of emitting off-gasses, emitting a certain threshold amount of off-gasses, or emitting off-gasses at a given rate of change, at the range of off-gas temperatures.
  • the off-gasses may be detected by a gas sensor, such as a metal oxide sensor, an electrochemical sensor, a total volatile organic compound sensor, an aerosol sensor, or any other common electronic gas sensing equipment and/or method capable of detecting different types of gasses.
  • a precursor event e.g., cell temperature below cell venting temperature
  • a precursor event may be detected for any type of battery cell encapsulated with a selected outgassing material with known outgassing properties, without the need to determine battery electrolyte variables.
  • Encapsuling a battery cell with a selected outgassing material may also provide the ability to customize a sensor for one or more specific off-gas components with known and consistent properties. Accordingly, by monitoring battery conditions using a known, controlled, and consistent outgassing material mounted on the battery itself, sensors can be used to accurately predict thermal runaway independent of battery technology or materials. Furthermore, the outgassing material may also be chosen or tailored for a given sensor technology.
  • a gas sensor may be configured to detect a thermal runaway event based on one or more off-gasses emitted by a battery pack.
  • the battery pack may comprise one or more battery cells encapsulated with an outgassing material such that, at a given temperature, the outgassing material may emit off-gasses detectable by the gas sensor.
  • the outgassing material comprises a polymer treated, imbued, coated, engineered, or otherwise incorporated with one or more chemical components including a specific vapor pressure, to emit off-gasses detectable by the gas sensor at a given temperature.
  • the given temperature may comprise a temperature sufficiently below a temperature when thermal runaway occurs (approximately 150°C/302°F), or below a temperature when cell venting starts to occur (approximately 134°C/272°F).
  • the given temperature may be in the range of 120°C - 140°C (248°F - 284°F).
  • other outgassing materials with various outgassing temperatures may also be selected, for example for various other battery types comprising different thermal runaway temperature characteristics or curves.
  • the disclosed outgassing material may be placed in intimate contact with the battery cell itself such that the temperature of the battery cell and the outgassing material will be in equilibrium, thus enabling the off-gassing of the outgassing material to represent the temperature of the battery cell.
  • Properties of the outgassing material may correspond to temperature and outgassing conditions that would enable a gas sensor to detect a temperature threshold comprising an established temperature, e.g., below cell venting or thermal runaway temperatures, via the detection of outgassing. When the threshold temperature is exceeded, the outgassing material may off-gas at a predicable rate and temperature.
  • the gas sensor may functionally act as a temperature sensor and indicate a temperature of the outgassing material as reaching a specific temperature to cause outgassing.
  • isoamyl acetate an organic ester
  • isoamyl acetate may be incorporated (e.g., seeded) in an outgassing material, such as a polymer, for encapsulating a battery cell.
  • the isoamyl acetate would not evaporate at ambient conditions, but can be detectable by certain sensors, such as VOC sensors when the polymer reaches temperatures that exceed the off-gas temperature threshold of the isoamyl acetate.
  • the temperature at which the outgassing material outgasses the ester could be chosen so that it represents a temperature below thermal runaway temperature.
  • the disclosed outgassing material may also be incorporated with a color indicator upon reaching a threshold temperature to provide a visual indication of an affected battery cell.
  • a polymer selected as an outgassing material may be embedded with a thermochromic additive that causes the polymer to change color with exposure to a specific amount of heat, such as any temperature above a range of 130°C - 150°C (266°F - 302°F).
  • the incorporation of a thermochromic element to an outgassing material may provide an indication of which of a plurality of battery cells (e.g., of a battery pack) have been exposed to excessive temperatures indicative of potential damage without the need to test each of the plurality of battery cells. Such a feature may be beneficial to technicians or manufacturers when servicing or repairing a battery pack.
  • Methods for incorporating a temperature activated color indication in an outgassing material, such as a polymer may be implemented through techniques known by one of ordinary skill in the art.
  • FIG. 2 presents an example battery cell unit 200 according to an embodiment of the present disclosure.
  • the battery cell unit 200 comprises a battery cell body 202 and an outgassing material 204.
  • Battery cell body 202 may comprise a container including a cathode, an anode, and electrolyte that are sealed within the container.
  • battery cell body 202 comprises a lithium battery cell.
  • the battery cell body 202 may comprise other types of battery cells known to one of ordinary skill in the art.
  • battery cell body 202 is depicted as a rectangular shape, however, embodiments of the present disclosure may be implemented for any type of battery type or form factors, such as cylindrical, prismatic, or pouch.
  • battery cell body 202 is depicted as being enclosed in outgassing material 204.
  • battery cell body 202 may include exposed contact portions or connection leads breaching the outgassing material 204 for making electrical connections.
  • a battery cell body 202 may be wrapped with outgassing material 204 comprising a polymer sleeve to insulate the anode and prevent shorting to external conductive surfaces.
  • the polymer may comprise a non-conductive heat shrink polymer that conforms with the body of a battery cell body 202.
  • a battery cell body 202 may comprise a casing attached with the disclosed outgassing material in the form of a polymer film.
  • Outgassing material 204 may comprise chosen material properties corresponding to a specific temperature and/or outgassing condition that causes outgassing material 204 to generate off-gas 208.
  • Off-gas 208 may comprise one or more gas constituents that evolve over a temperature range (e.g., a range of temperatures approximately between 120°C - 140°C (248°F - 284°F).
  • the temperature threshold may comprise an established temperature of cell venting or prior to cell venting.
  • the encapsulation of battery cell body 202 with outgassing material 204 may comprise outgassing material 204 to be in intimate contact with battery cell body 202.
  • Heat transfer 206 causes the temperature of the battery cell body 202 and the outgassing material 204 to be in equilibrium, thus enabling off-gas 208 to represent the temperature of the battery cell body 202 upon reach the temperature threshold.
  • the outgassing material 204 may generate off-gas 208 at a predicable rate and temperature.
  • the presence of, a certain threshold amount (e.g., measured by concentration units, such as parts-per-million (ppm), and/or rate of change of off-gas) of, and/or a target rate of change of off-gas 208 may be used to enable a gas sensor to detect a temperature threshold indicative of cell venting or pre-cell venting.
  • a gas sensor may be configured with a battery pack comprising one or more battery cells (e.g., battery cell body 202) encapsulated with the disclosed outgassing material (e.g., outgassing material 204) may be coupled to a battery management system.
  • the gas sensor may transmit a signal to the battery management system to indicate that at least one battery cell of the battery pack has reached a given temperature preceding a thermal runaway condition based on outgassing from the outgassing material.
  • the battery management system may shut down or disable utilization of the battery pack, generate a warning signal, and transmit the warning signal to, for example in the case of an electric vehicle, an on-board computer indicative of a dangerous condition.
  • FIG. 3 presents an example battery system incorporating thermal runaway detection according to an embodiment of the present disclosure.
  • Battery system 300 comprises battery pack 302, gas sensor 306, battery management system 308, and charge controller 312.
  • Battery pack 302 may comprise a plurality of battery cells (e.g., battery cell body 202), where each cell may be encapsulated or wrapped in the outgassing material, as described according to various embodiments of the present disclosure.
  • the plurality of battery cells may be configured in series, parallel, or a combination thereof to deliver a desired voltage, capacity, and/or power density.
  • Each of one or more of the plurality of battery cells may comprise a threshold operating temperature prior to off-gassing, e.g., a range of temperatures approximately between 120°C - 140°C (248°F - 284°F).
  • off-gas 310 may be released from battery pack 302.
  • Off-gas 310 may comprise one or more gasses comprised in the outgassing material that are released as a result of heating to a critical temperature to cause the outgassing material to outgas.
  • the gas sensor 306 may comprise a sensor capable of detecting the off-gassing emitted from the outgassing material regardless of the composition of off-gas 310.
  • the gas sensor 306 may comprise a metal oxide sensor, an electrochemical sensor, a total volatile organic compound sensor, an aerosol sensor, or any other common electronic gas sensing equipment and/or method capable of detecting different types of gasses. Accordingly, system 300 may provide for early detection of thermal runaway by monitoring for off-gassing from outgassing material when one or more battery cells within battery pack 302 reach certain temperatures below cell venting and/or thermal runaway temperatures.
  • gas sensor 306 may detect the presence of, a certain threshold amount of, and/or a target rate of change of off-gas 310 and transmit a data signal corresponding to or representative of an event, e.g., detection of off-gas 310, to battery management system 308.
  • the data signal comprises an indication that at least one of the one or more battery cells has reached the range of off-gas temperatures based on the detection of the off-gas.
  • Battery management system 308 may perform appropriate functions to prevent further increase in temperature and damage to battery pack 302 based at least in part on the data signal from gas sensor 306.
  • Battery management system 308 may comprise a computing device or processor configured to protect and ensure safe operation of battery pack 302. For example, battery management system 308 may monitor battery cells, provide protection to the battery cells, optimize performance of the battery cells, and report operational status of the battery cells to a device control unit.
  • battery management system 308 may monitor or receive data signals from gas sensor 306. As such, battery management system 308 may be configured to determine early-stage thermal runaway based at least in part on data signals representative of a detection of off-gas 310 by gas sensor 306. The battery management system 308 may monitor the status of battery pack 302 (e.g., including the detection of off-gas 310) and communicate with charge controller 312 to manage charging parameters of battery pack 302 based at least in part on the monitoring.
  • Charge controller 312 may comprise a computing device or processor configured to provide charging of battery pack 302 at given currents and voltages.
  • a processor may comprise programmable logic devices, microprocessors, multi-core processors, coprocessing entities, application-specific instruction-set processors (ASIPs), microcontrollers, and/or controllers.
  • ASIPs application-specific instruction-set processors
  • FIG. 4 presents an example flow diagram illustrating an exemplary method for monitoring for a thermal runaway pending event according to some embodiments of the present disclosure.
  • the example method 400 may be executed by a computing device comprising memory and one or more processors.
  • the computing device may be associated with a battery monitoring system, such as a battery management system.
  • the computing device samples off-gas measurement data associated with a battery package comprising one or more battery cells.
  • the one or more battery cells may be encapsulated with outgassing material, as described according to various embodiments of the present disclosure.
  • the computing device may receive off-gas measurement data from one or more gas sensors.
  • the computing device may be communicatively coupled to one or more gas sensors configured to detect presence, amount, and/or concentration of one or more gasses.
  • the one or more gas sensors may be capable of performing off-gas measurement of one or more off-gasses associated with outgassing material encapsulating the at least one battery cell of the battery package.
  • the off-gas measurement data may comprise one or more values based on the presence, amount, and/or concentration of one or more gasses detected by the one or more gas sensors.
  • off-gas measurement data sampled and received from the one or more gas sensors may comprise a quantitative value (e.g., ppm), a qualitative value (e.g., high, medium, low), or a Boolean/binary value (e.g., yes/no) indicative of an off-gas event.
  • a quantitative value e.g., ppm
  • a qualitative value e.g., high, medium, low
  • a Boolean/binary value e.g., yes/no
  • the example method proceeds to step 404, where the computing device determines a temperature or a rate of temperature change of the one or more battery cells based on the off-gas measurement data.
  • the presence of, a certain threshold amount of, and/or a target rate of change of off-gas may be associated with a specific battery cell temperature or a range of battery temperatures (e.g., 120°C-140°C (248°F - 284°F)) based on specific outgassing properties of the outgassing material encapsulating the at least one battery cell of the battery package.
  • the absence of, a below threshold amount of, and/or a non-target rate of change of off-gas may be associated with temperatures below a specific battery cell temperature.
  • step 404 the example method proceeds to step 406, where the computing device determines whether there is a thermal runaway pending event based on the temperature of the one or more battery cells and/or the rate of temperature change of the one or more battery cells, as indicated by the off-gas measurement data provided by the one or more gas sensors. If the temperature of the one or more battery cells is not associated with a thermal runaway pending event, the example method proceeds back to step 402, wherein the computing device continues to sample off-gas measurement data associated with the battery package.
  • the example method proceeds to step 408, wherein the computing device performs one or more actions based on the thermal runaway pending event.
  • the one or more actions may comprise shutting down or disabling utilization of the battery pack, generating a warning signal, and transmitting the warning signal to, for example in the case of an electric vehicle, an on-board computer indicative of a dangerous condition.

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  • Chemical & Material Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Materials Engineering (AREA)
  • Battery Mounting, Suspending (AREA)
  • Gas Exhaust Devices For Batteries (AREA)
  • Secondary Cells (AREA)
  • Protection Of Static Devices (AREA)
  • Charge And Discharge Circuits For Batteries Or The Like (AREA)
EP24151564.2A 2023-02-06 2024-01-12 Encapsulation d'élément de batterie permettant la détection précoce d'emballement thermique de batterie Pending EP4465432A3 (fr)

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US18/165,121 US20240266668A1 (en) 2023-02-06 2023-02-06 Battery cell encapsulation enabling early detection of battery thermal runaway

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US10352777B2 (en) * 2015-01-07 2019-07-16 The Boeing Company Systems and methods for monitoring temperatures of batteries
CN107502025B (zh) * 2016-11-29 2019-11-22 北京交通大学 一种微胶囊温敏材料及其制备方法与应用
WO2019146564A1 (fr) * 2018-01-23 2019-08-01 Tdk株式会社 Feuille de détection de gaz et élément électrochimique comprenant une feuille de détection de gaz
US10992013B2 (en) * 2018-10-05 2021-04-27 Samsung Sdi Co., Ltd. Battery system for a vehicle and method for detecting an overheat situation of the battery system
JP7333393B2 (ja) * 2019-02-20 2023-08-24 リヴィアン アイピー ホールディングス，エルエルシー 電池セル監視用電池モジュールガスセンサ
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KR20220011859A (ko) * 2020-07-21 2022-02-03 현대모비스 주식회사 차량 배터리의 열폭주를 감지하는 배터리 장치 및 그 방법
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EP4465432A3 (fr) 2025-03-19
GB2628462A8 (en) 2025-03-12
GB2628462A (en) 2024-09-25
KR20240123246A (ko) 2024-08-13
GB2628462B (en) 2025-04-30
GB202400714D0 (en) 2024-03-06
CN118507806A (zh) 2024-08-16
US20240266668A1 (en) 2024-08-08

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